Fiber Reinforced Plastic Member With Progressive Strength Variation
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Solution Overview
Problem
Existing methods for producing fiber-reinforced plastic members struggle to efficiently achieve varying strengths in different areas, leading to inefficient stress transmission and increased process complexity due to disconnected reinforcement fibers and additional impregnation procedures.
Innovation Solution
A fiber-reinforced plastic member comprising a continuous variation layer with progressively inclined reinforcement fibers and a reinforcing layer with intersecting fibers in a reticular pattern, combined with a metal layer, which are integrated through a heat press process to form a composite with progressive strength variation and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement fiber mesh plates are layered with different directions to achieve varying strengths in different areas, then the strength requirement is satisfied, but the stress transmission efficiency decreases due to disconnected portions between reinforcement fibers
Solution Approach 1:
The reinforcement fibers are pre-aligned in specific directions within the continuous variation layer before bonding to the metal member, ensuring optimal stress transmission paths are established in advance. This preliminary arrangement of fibers in continuous directions eliminates discontinuities that would otherwise interrupt stress flow.
Solution Approach 2:
The invention creates a composite structure combining metal members with fiber-reinforced plastic layers where the fibers are continuously aligned. This composite material approach allows the fiber layer to act as an integrated reinforcement that maintains continuous stress transmission while providing area-specific strength variations through controlled fiber orientation.
2Strength
If the number of reinforcement fiber mesh plates is increased to satisfy required strengths, then the strength requirement is met, but the manufacturing efficiency decreases
Solution Approach 1:
Instead of uniformly increasing the number of fiber mesh plates throughout the structure, the invention applies fiber reinforcement with specific orientation patterns only in areas where strength is required. The continuous variation layer contains fibers oriented at different angles in different regions, providing localized strength enhancement without unnecessary material addition in areas where less strength is needed.
Solution Approach 2:
The invention changes the orientation parameter of reinforcement fibers continuously across different areas of the metal member. By varying the fiber angle parameter from 0 degrees in high-stress areas to other angles in lower-stress areas, the structure achieves varying strength characteristics without increasing the overall number of fiber layers, thereby maintaining manufacturing efficiency.
3Stability of the object's composition
If additional impregnation procedures are added to impregnate reinforcement fiber mesh plates with synthetic resin, then the composite formation is achieved, but the number of processes increases
Solution Approach 1:
The invention merges the fiber reinforcement function and the synthetic resin impregnation function into a single integrated layer. The continuous variation layer combines both the reinforcement fibers and the synthetic resin matrix in one unified structure that is bonded directly to the metal member, eliminating the need for separate impregnation steps that would otherwise be required for discrete fiber mesh plates.
Solution Approach 2:
The invention extracts the synthetic resin impregnation step from the traditional multi-step RTM process and integrates it directly into the fiber reinforcement layer construction. By forming the continuous variation layer with pre-impregnated fibers, the process removes the need for separate mold cavity impregnation procedures, reducing overall process complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables efficient stress transmission and strength variation in different areas, reducing the weight of the vehicle body while simplifying the manufacturing process by eliminating the need for additional bonding procedures and enhancing the overall durability of the fiber-reinforced plastic member.
Implementation Method 1
layered to each other and integrally pressed to thereby form the fiber-reinforced plastic member
Data Source
AI summary
The fiber-reinforced plastic member includes a continuous variation layer which includes a synthetic resin constituting a base and a plurality of reinforcement fibers embedded in the synthetic resin, and a reinforcing layer which is attached to the continuous variation layer to constitute the fiber-reinforced plastic member for a vehicle and is composed of a synthetic resin constituting the base and a plurality of reinforcement fibers.In particular, the plurality of reinforcement fibers in the continuous variation layer are arranged so as to be inclined with respect to a longitudinal direction of the fiber-reinforced plastic member for a vehicle and angles of the reinforcement fibers with respect to the longitudinal direction of the fiber-reinforced plastic member progressively varying along the longitudinal direction and the plurality of reinforcement fibers in the reinforcing layer are embedded in the synthetic resin and intersecting each other in a reticular pattern.